Zero (chip-out) tolerance

 

After making a relief cut with a
1/4"-diameter router bit, we used
a jigsaw to create clearance for
the riving knife.

 

A relief area for the arbor assembly
proves necessary when raising the
blade to cut 2" or thicker workpieces.

Jigsaw a riving-knife slot

You'll also have to cut relief holes or slots for blade guards, splitters, or riving knives. You can do this with your tablesaw and 10" blade--with the original insert installed--if the relief exits the back of the insert. If it does not, use a jigsaw, photo right. You might also have to relieve the bottom face for such things as the arbor assembly and flange, or for parts specific to the original insert, photo below right. Machine these shallow relief areas at the drill press with a Forstner bit or on a router table.